INTORQ BFK468 – the new performance standard
High-performance drives are achievingever higher motor speeds and drivetorques. Although performancerequirements are increasing, less andless space is generally available forinstalling the brake. Innovative multipole technology is thebasis for a new performance class.
Features| Up to twice the braking torque
compared to the BFK458| Fixed or adjustable
braking torque| Short operating times| Large working air gap means long
maintenance intervals
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Product key INTORQ BFK468-òòò
Sizes18, 20, 25, 31
Stator designE – Adjustable (braking torque can be reduced using
torque adjustment ring) N –Non-adjustable
B F K 4 6 8 - òò ò
Product group: Brakes
Product family: Spring-applied brakes
Type
Size
Design
Flange
SealHub
Rotor
Complete statorbrake module N
Plug
Shaft sealing ring
Complete statorbrake module E
Manualrelease
BFK468 modular system
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List of abbreviations
P [kW] Drive motor powerPmax [W] Maximum power when releasing the
brake with overexcitationP20 [W] Coil power at 20°C in continuous
operation with holding current deratingMK [Nm] Rated torque of brake∆n0 [rpm] Initial relative speed of the brake t1 [s] Engagement time, t1 = t11 + t12
t2 [s] Disengagement time(time from the beginning of the torquedrop until 0.1 MK is reached)
t3 [s] Slipping time(time during which a relative movementoccurs between input and output withbrake applied)
t11 [s] Delay time(time from disconnecting the voltage untilthe torque begins to rise)
t12 [s] Rise time of braking torqueQperm [J] Max. permissible friction energy per
switching cycleSh [h-1] Operating frequency, i.e. the number of
periodical brake operationsSlü Rated air gap
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INTORQ I BFK468 spring-applied brake I en 2/2007
Contents
Product information 6
Principle of operation 7
Technical dataBraking torques 8Rated data 10Operating times 11Service life and wear 12
AccessoriesManual release/flange/cover ring 13Brake cover 14Microswitch 14
Bridge/half-wave rectifier 15
Available variants 17
Sales and service around the world 18
Example applications
Slew, lift, move – whenever cranes arein motion, INTORQ BFK468 spring-applied brakes are never far away. A special version is also available fortheatre applications.| Brake motors| Storage technology| Escalators| Cranes| Dockyards| Stage machinery
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INTORQ I BFK468 spring-applied brake I en 2/2007
Product information
INTORQ BFK468 spring-applied brake
A powerful and complete range| 4 sizes| Standard voltages 205/103 V, 360/180 V (release
voltage/holding voltage)| Torque range from 100 – 2400 Nm
Versatile| Modular structure for virtually all applications| Connection compatible with the BFK458 range
Torque transmission| Designed for dry running
Ready for operation immediately| Preset air gap, quick and easy mounting| Special machining of the friction surfaces ensures
that the rated torques are achieved after very few switchingoperations.
| No fixed bearing is required on the brake
Durable| The insulation system to temperature class F (155°C)
ensures that the winding has a long service life| Brakes are designed for 100 % duty time (with holding
current derating) using an INTORQ bridge/half-waverectifier
| Long rotor/hub connection with low rate of wear and atried-and-tested involute gear
| Asbestos-free fiction linings with low rate of wear
Reliable| The certified ISO 9001 and ISO 14001 quality system
provides the basis for consistently high-quality products| Manufacture and testing to VDE 0580
Options| Manual release for sizes 18–25, both directions can be
used for release| Noise-reduced designs| Different types of corrosion protection and enclosures| Microswitches used to monitor air gap and wear
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INTORQ I BFK468 spring-applied brake I en 2/2007
Principle of operation
INTORQ BFK468 spring-applied brake
Brake module E + rotor + hub + flange Brake module N + rotor + hub + flange
INTORQ BFK458 spring-applied brakes are single-discbrakes with two friction surfaces. When a de-energised,several compression springs are used to generate thebraking torque through friction. The brake is releasedelectromagnetically. During the braking, the rotor, which canslide axially on the hub, is pressed against the counterfriction face via the armature plate, by means of thecompression springs. When the brakes are applied, an airgap slü is present between the armature plate and the stator.The stator's coil is energised with DC voltage in order torelease the brake.
The resulting magnetic flux works against the spring force todraw the armature plate to the stator. This releases the rotorfrom the spring force and allows it to rotate freely. Brakemodule E supports the use of the torque adjustment ring (8)to reduce the braking torque.
Stator
Torque adjustment ring
RotorCompression spring
Hub
Armature plate
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INTORQ I BFK468 spring-applied brake I en 2/2007
Technical data
Braking torques
Depending on the individual application, the graduatedtorques listed in the tables below are available.The braking torque on brake module E can be reducedusing the torque adjustment ring located in the stator. The torque adjustment ring can be unscrewed to amaximum dimension of h1max (see table on page 9).
It should be noted that the engagement and disengagementtimes change in accordance with the braking torque.
Size 18 20 25 31
Rated torque Torque Rated torque Torque Rated torque Torque Rated torquereduction E reduction E reduction E
1) per detent 1) per detent 1) per detent 1)
[Nm] [Nm] [Nm] [Nm] [Nm] [Nm] [Nm]
230 N
100 N/E 6.4 170 N/E 19.8 260 N/E 16.5
115 N/E 6.4 200 N/E 19.8 300 N/E 8.2 720 N
130 N/E 6.4 230 N/E 9.9 350 N/E 8.2 960 N
150 N/E 3.2 260 N/E 9.9 400 N/E 8.2 1200 N
165 N/E 3.2 300 N/E 19.8 445 N/E 16.5 1440 N
185 N/E 6.4 345 N/E 19.8 490 N/E 8.2 1680 N
200 N/E 6.4 400 N/E 19.8 520 N/E 16.5 1920 N
235 N/E 6.4 440 N/E 19.8 600 N/E 16.5 2160 N
265 N/E 6.4 480 N/E 19.8 700 N/E 16.5 2400 N
300 N/E 6.4 520 N/E 19.8 800 N/E 16.5
| N ... Braking torque for design N (without torque adjustment ring)
| E ... Braking torque for design E (with torque adjustment ring)
Holding brake with emergency stop operation(slümax approx. 2.0 x slü)
Service brake(slümax approx. 4.0 x slü)
Standard braking torque
Rated torques in relation to the relative speed ∆n = 100 rpm
Depending on the rated torque(spring configuration) the angle of rotation for reducingthe braking torque on basicmodule E can be 60°, 120° or180°
1) Minimum braking torque for run-in friction pairs
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INTORQ I BFK468 spring-applied brake I en 2/2007
Technical data
BFK468 with manual release and flange
Dimensions
Size dH7 d1 d2 d3 d4 d5 d6 d7 d8 d9 d10 d11 d12 d13 di
18 30/35/40/45 6xM8 196 75 4xM8 95 217 217 116 62 77 220 24 14 129
20 35/40/45/50 6xM10 230 85 4xM10 110 254 254 135 72 90 257 36 20 148
25 40/45/50/55/60/65/70 6xM10 278 115 4xM10 140 302 302 180 85 120 305 36 25 199
31 80 8xM16 360 150 4xM16* 200 390 390 200 110 150 - – – 243
Size da h h1 h1 h2 h3 h4h5 h6 h7 h8 l l1 l2 l3 sair � �
min. max. max.
18 174 83.1 89 96.5 2.75 11 70.6 385 128 34 108.1 35 600 15.3 9.6 0.4 51.5° 8°
20 206 97.6 104 110 3.5 11 82.6 650 150 69 122.6 40 600 10.4 12 0.4 51.5° 8°
25 254 110.7 118 128 4.5 12.5 95.7 1045 173.5 69 135.7 50 600 17.3 12 0.5 51.5° 6.5°
31 330 149 – 173 10 10 – – – – – 70 600 33 19 0,5 5° –
| dH7: Hubs with a keyway in accordance with DIN 6885/1-P9 can only be used for thebore diameter indicated (d) up to the maximum standard braking torque. The dimensionsof the shaft/hub connection for higher braking torques are to be determined inconjunction with the manufacturer.
| * 4x M16 rotated by an angle of 45° in relation to illustration
| l1: Connecting cable length
| m: Mass in kg
| All dimensions in mm
l1
Sizes 18–25 Size 31
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INTORQ I BFK468 spring-applied brake I en 2/2007
Technical data
Rated data
Size P20 1) P20 sairmax sairmax max. min.2) JAlurotor Mass Massholding releasing to standard torque increased torque adjustment rotor thickness brake stator
[W] [W] [mm] [mm] [mm] [mm] [kgcm2] assembly [kg] [kg]
18 88 352 1.5 1.0 3.0 10.0 29 19 13.4
20 99 396 1.5 1.0 4.0 12.0 73 32 20
25 117 469 1.8 1.2 4.5 15.5 200 50 31
31 221 884 2 1.5 3 15 457 73.2 55.1
| P20: Coil power at 20 °C in W
| 1) with holding current derating, possible deviation of up to + 10 % depending on supply voltage selected
| 2) The friction lining is dimensioned so that the brake can be readjusted at least 2 times.
Braking torques, depending on speed and permissiblelimit speeds
Size Reference variable Braking torque at ∆n0 [rpm ] Max. speedrated torque ∆n0maxat ∆n =100 rpm 1500 3000 max.
[%] [%] [%] [%] [rpm ]
18 100 77 70 66 4.400
20 100 75 68 66 3.700
25 100 73 66 66 3.000
31 100 69 _ _ 2300
| As speed increases, so does wear
Noise-reduced designs
The noise reduction required in many applications can beachieved in two ways:
1. Impact-noise-reduced armature plateThe brake's operating noise can be minimised using specialdamping elements, which are installed between the poleface and the armature plate as shock absorbers.
2. Noise-reduced aluminium rotorRattling noises, which can occur in the rotor/hubconnection, for example, during frequency inverteroperation, or as a result of load alternation, or non-constantspeeds, are reduced by using a rotor with a plastic sleeve.With size 31, the noise is reduced by inserting an O-ring between the rotor and the hub.
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INTORQ I BFK468 spring-applied brake I en 2/2007
Technical data
Operating times
The listed operating times apply to DC switching with ratedair gap slü, a warm coil and standard rated torque. The timesshown are mean values. The engagement time t1 isapproximately 5 times higher for AC switching.
The engagement time t1 increases if inching mode is shorterthan the overexcitation time of the bridge/half-waverectifier.
AC switching
DC switching
t11 = Delay time
t12 = Rise time ofbraking torque
t1 = Engagement timet2 = Disengagement timet3 = Slipping time
Torque time characteristic, dependent onexcitation voltage
Cha
ract
eris
tic to
rque
Exci
tatio
n
Time
Time
Size Braking torque Maximum permissible Transition Operating times [ms] 1)
rated value at switching energy with operating frequency at Slür∆n =100 rpm single operating frequency Switching on DC side DisengagementMK QE Sh
[Nm] [J] [h-1] [t11] [t12] [t1] [t2]
18 150 60.000 20 26 30 56 70
20 260 80.000 19 56 112 168 106
25 400 120.000 15 62 135 197 120
31 1200 300.000 13 65 133 198 250
| 1) Operating times valid for 205 V DC coils
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INTORQ I BFK468 spring-applied brake I en 2/2007
Technical data
Permissible friction energy Qperm depending onoperating frequency Sh
Service life and wear
The brake has to be adjusted when slümax is reached. Thefriction energy to be withstood up to this point is dependenton a number of factors: in particular, the inertias to bebraked, the braking speed, the operating frequency and theresulting temperature on the friction surfaces. For thisreason, no universal value for all operating conditions canbe given in respect of the amount of friction energy thatcan be handled before adjustment is required.
In addition, increased wear should be expected withvertical mounting.
The BFK468 can be adjusted when the maximumpermissible working air gap is reached (slümax). Thedimensioning of the friction lining allows adjustment to becarried out at least twice.
Where the amount of friction energy per switchingoperation is low, the brake's mechanical components canimpose limitations in terms of service life. In particular, therotor/hub connection, springs, armature plate and sleevesare subject to operational wear. The expected service life ofthe standard design is around 1 million load alternations.Solutions that are optimised in terms of service life areavailable in cases where a longer service life is required(consult the manufacturer).
MaintenanceBrakes are components which are subject to a great deal ofwear. When installing the brake, it must be ensured that itcan be easily accessed for inspection and maintenancepurposes. Intervals between inspections should be set inaccordance with the expected service life and load. Formore information, please see the Operating Instructions.
1000000
100000
10000
1000
1001 10 100 1000 10000
Operating frequency Sh [h-1]
Swit
chin
g en
ergy
Q [J
]
Sizes31
25
20
18
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INTORQ I BFK468 spring-applied brake I en 2/2007
Accessories
Manual release
The manual release is used to release the brake by hand andcan also be retrofitted. It springs back into its originalposition (0 setting) automatically after operation. Therelease screws that are carried in a ball joint are only intension. When installing the manual releases, care must betaken when setting dimension "s":
Caution:Even with a reduced rated torque, the air gap must bereadjusted when slümax is reached for safety reasons.
Flange
If no suitable counter friction face is available, a flange onwhich the seal can be installed can be used.
Seal
To a large extent, the cover ring prevents the exit or ingressof dust, humidity, dirt, etc., out of or into the braking area.The cover ring is inserted into the groove on the stator. If nosuitable groove is available on the counter friction face, werecommend the use of a flange.
Manual release
Flange Seal
Size slü+ 0.1 s + 0.1- 0.05
[mm] [mm]
18 0.4 2
20 0.4 2
25 0.5 2.5
31 – –
Slü
S
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INTORQ I BFK468 spring-applied brake I en 2/2007
Accessories
Brake cover
Brake module E, N + cover = encapsulated designA cover can be mounted onto basic module E and basicmodule N as an option, to protect the brake from water anddust (enclosure acc. to IP 65). This cover cannot becombined with a manual release.
Size d1 d2 d3 H8 d4 d5 h h1 h2 h3 1)
18 285 268 238 4x6.6 M20x1.5 115 60 29 3
20 330 314 283 4x9 M20x1.5 131 69 35 3
25 390 368 328 4x9 M20x1.5 142 78 40 3
| 1) Recommended recess length on motor endshield
Microswitch
The brake can be fitted with a microswitch for the purpose ofmonitoring the release or wear. The microswitch can be builtinto the circuit as an NC contact or an NO contact.
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INTORQ I BFK468 spring-applied brake I en 2/2007
Bridge/half-wave rectifier
BEG-561-òòò-òòò
BFK468 brakes must only be operated with a bridge/half-wave rectifier. Following a fixed overexcitation time, the bridge/half-waverectifiers switch from bridge rectification to half-waverectification. Terminals 3 and 4 are in the DC circuit of thebrake. With switching on the DC side, integrated overvoltageprotection at terminals 5 and 6 limits the induced voltagepeak (see "Reduced switch off times" diagram).
Technical data
Dimensions
3,4
38
4
42
3,4
52,6
21,5
1,84,3
46,9-0,1
51,9-0,1
440 V~ 1,5/0,75A t =0,30s¸
13169140
Typ BEG-561-440-030-1
5
Rectifier type Bridge/half-wave rectifier
Output voltage with bridge rectification 0.9xU1
Output voltage with half-wave rectification 0.45xU1
Ambient temperature (storage/operation) [°C] -25...+70
U1 = Input voltage (40 to 60 Hz)
Type Input voltage U1 (40 Hz to 60 Hz) Max. current Imax Overexcitation time to (±20%)
Min. Rated Max. Bridge Half-wave At U1min At U1r At U1max
[V~] [V~] [V~] [A] [A] [s] [s] [s]
BEG-561-255-030160 230 255
3.0 1.5 0.430 0.300 0.270
BEG-561-255-130 3.0 1.5 1.870 1.300 1.170
BEG-561-440-030-1230 400 440
1.5 0.75 0.500 0.300 0.270
BEG-561-440-130 3.0 1.5 2.300 1.300 1.200
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INTORQ I BFK468 spring-applied brake I en 2/2007
Bridge/half-wave rectifier
BEG-561-òòò-òòò
Fixing options Permissible current load – ambient temperature
� Screw mounting with metal surface (good heat dissipation)� Other mounting (e.g. adhesive)
Connection
� Mains � Bridge � Coil
Shortened release timesIn the case of switching on the DC side (shorter releasetimes) switching must also occur on the AC side! Otherwise,overexcitation will not occur on restarting.
Assignment of the bridge/half-wave rectifier to the brake size
Release times Release timeson the AC side on the DC side
� �� � �
�
�
Brakes Half-wave rectifier Supply voltage Coil voltagetype type release/holding
[V AC] [V DC]
BFK468-18
BFK468-20BEG-561-255-030
230 +-10% 205/103
BFK468-25 BEG-561-255-130
BFK468-18
BFK468-20BEG-561-440-030-1
400 +-10% 360/180BFK468-25
BFK468-31BEG-561-440-130
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INTORQ I BFK468 spring-applied brake I en 2/2007
Available variants
INTORQ BFK468òòò
Complete stator
Size ò 18 ò 20 ò 25 ò 31
Design ò E (with torque adjustment ring, sizes 18, 20, 25)ò N (without torque adjustment ring)
Brake voltage ò 205 V/103 V DC for 230 V AC supply voltage (not available for size 31)ò 360 V/180 V DC for 400 V AC supply voltage
Braking torque Nm (see graduated torques)
Cable length ò Standardmm (from 100 mm to 1000 mm in 100 mm steps,
from 1000 mm to 2500 mm in 250 mm steps)
Manual release fitted ò (not available for size 31)
Armature plate ò Standard ò Chromium-plated
Microswitch ò Switching function monitoring (release control)ò Wear monitoring
Operating noise ò Reduced
Accessories
Rotor ò Standard ò Noise-reduced (rotor with sleeve)
Hub mm (for bore diameter, see Dimensions)
Fixing ò For mounting on flange/motorscrews set ò For mounting on flange with through holes
Sealing ò Sealò Shaft sealing ring (shaft diameter on request)ò Cap
Brake cover ò 18 ò 20 ò 25
Electrical accessories
Bridge/half-wave rectifier ò BEG-561-255-030ò BEG-561-255-130ò BEG-561-440-030-1ò BEG-561-440-130
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